Development of High-Efficiency Oxy-fuel IGCC System...Contents 1 Background & objective 2 Concept of High-Efficiency Oxy- fuel IGCC 3 Project status 1) Experimental study using 3TPD

Central Research Institute of Electric Power Industry

Development of High-Efficiency Oxy-fuel IGCC System

Energy Engineering Research Laboratory

2013

3rd Oxy-fuel Combustion Conference

15/9/2013

Y. Oki*, K. Kidoguchi, S. Umemoto, H. Watanabe,Y. Nakao, M. Kobayashi, S. Hara

1

Contents 1 Background & objective

2 Concept of High-Efficiency Oxy-fuel IGCC

3 Project status 1) Experimental study using 3TPD gasifier

2) Modeling of O2/CO2 gasification reaction

and numerical simulation of gasifier

3) Development of countermeasure

for carbon deposition in hot gas clean-up system

4) Consideration toward next step 2013 2









Background and Objective

2013 4

●To reduce GHG (CO２) emission,

Japanese utilities make efforts to

→Improve thermal efficiency （250MW IGCC Demonstration Project) →Expand Biomass Co-firing （1～3wt% ） ●CCS is regarded as an option to cope with global warming → However, decreases efficiency and increases its cost

Development of Innovative Carbon capture system

with high efficiency

Source: http://www.ccpower.co.jp/

Impact of CO2 capture on net efficiency

2013 5 IGCC PC NGCC

Without CO2

capture With CO2 capture

●Impact of CO2 capture on efficiency (Efficiency is reduced around 20%)

Source: “Cost and Performance Baseline for Fossil Energy Plants”, DOE/NETL-2007/1281

2013 6

Impact of CO2 capture on net efficiency

0

10

20

30

40

50

1 2 3 4 5 6

Source:U.S.DOE NETL Report "Cost and Performance Baseline for Fossil Energy Plants-Volume1 Rev.2 DOE/NETL 2010/1397 (Nov.2010)

Revised data on IGCC

Effi

cien

cy %

(HH

V B

ases

)

Conv Capt Conv Capt Conv Capt

GE IGCC E-Gas IGCC Shell IGCC

Conventional Power Station with CO2 Capture

2013 7

１．Post-combustion

2. Oxy-fuel Combustion

3. Pre-combustion

Chemical absorption : Commercialized Development issues: Decrease of energy for CO2 capture

Coal

AirBoiler

Coal

Oxygen Boiler

Coal

Air/ Oxygen

Gasifier

Demonstration stage Development issues: Decrease of energy for Air Separation Unit

Demonstration stage Development issues: Decrease of energy for CO2 capture









New IGCC system to capture CO2

2013 9

Coal

OxygenGasifier

Coal

Oxygen Gasifier

Gasifier Gas Clean Up

Gas Clean Up

Storage

Gas Turbine

High-efficiency Oxy-fuel IGCC

Existing IGCC with CO2 Capture

2013 10

Results of preliminary estimation (CRIEPI Report : M07003)

* Source : “Cost and Performance Baseline for Fossil Energy Plants”, DOE/NETL-2007/1281

High-Efficiency Oxy-fuel IGCC Conventional IGCC*

NO YES

CRIEPI

NO NO YES YES

GE SHELL

Net Thermal Efficiency

Comparison between with CO2 Capture and without CO2 Capture (1300C class GT)

Net Power Output

0

200

400

600

800

1000

Net

Pow

er O

utp

ut

MW

0

10

20

30

40

50

Net

Th

erm

al E

ffic

ien

cy (

HH

V)

%

CO2 Capture Gasifier

Net Thermal Efficiency

0

200

400

600

800

1000

Net

Pow

er O

utp

ut

MW

0

10

20

30

40

50

Net

Th

erm

al E

ffic

ien

cy (

HH

V)

%

Net Power Output

CO2 Capture Gasifier

2013 11

Target of this project

0

10

20

30

40

50

1 2 3 4 5 6

Source:U.S.DOE NETL Report "Cost and Performance Baseline for Fossil Energy Plants-Volume1 Rev.2 DOE/NETL 2010/1397 (Nov.2010)

Revised data on IGCC

Effi

cien

cy %

(HH

V B

ases

)

Conv Capt Conv Capt Conv Capt

GE IGCC E-Gas IGCC Shell IGCC

Target efficiency 42%(HHV)

2013 12

Schematic Diagram of high-efficiency oxy-fuel IGCC System

2013 13

Outline of high- efficiency oxy-fuel IGCC System

CO2 separation unit is not required

2013 14



Semi-closed cycle GT system improves efficiency

2013 15



Gasifier performance is improved in O2/CO2 gasification system

Semi-closed cycle GT system improves efficiency

2013 16


Regenerative Heat Exchanger

2013 17

http://www.spp.co.jp/English/business/

Hot gas

Cool gas Cold gas

Warm gas

Heat exchange is accelerated by fin structure

2013 18

Schedule of NEDO project ( 1st Phase) 2008 2009 2010 2011～2013

1.O2- CO2 blown gasification technology

✓Experimental study by 3TPD gasifier ✓ Development of numerical simulation

tool ✓Clarification of basic gasification

reaction

2. Optimization of hot gas clean-up system at high CO concentration

3. Feasibility study of practical scale plant 4. Basic design of bench scale

plant system

Mid-term evaluation▼

<Acknowledgement> Most part of this presentaiion has been executed based on research funded by NEDO (New Energy and Industrial Technology Development Organization). Some works done by CRIEPI as in-house research.









CRIEPI 3TPD entrained flow gasifier

2013 20

Air, O2-enriched Air, O2, SteamGasifying Agent

Coal (Including Low Rank Coal)Fuel Types

2 MPaPressure

3 t/DayCapacity

Dry Feed SystemFuel Feed

Pressurized Entrained FlowType

Air, O2-enriched Air, O2, SteamGasifying Agent

Coal (Including Low Rank Coal)Fuel Types

2 MPaPressure

3 t/DayCapacity

Dry Feed SystemFuel Feed

Pressurized Entrained FlowType

2013 21

Effect of CO2 concentration (CRIEPI Report : M10016)

0

10

20

30

40

0.50 0.51 0.52 0.53 0.54空気比 [－]

チャ

ー生

成率

[％

]

□：CO2 0 vol％●：CO2 15 vol％○：CO2 25 vol％

Oxygen ratio (-)

2013 22

Effect of CO2 concentration (CRIEPI Report : M10016)

0

10

20

30

40

0.50 0.51 0.52 0.53 0.54空気比 [－]

チャ

ー生

成率

[％

]

□：CO2 0 vol％●：CO2 15 vol％○：CO2 25 vol％

Oxygen ratio (-)









Reaction model for CO2 gasification

2013 24

Pressurized Drop Tube Furnace Max.Pressure 2.0 MPa Max. Temp. 1,750℃

Reaction model for H2O/CO2 gasification

2013 25

(a) SF Char (b) DT Char Model 1 Model 1

Model 2 Model 2

Proposed model Proposed model

Simulation result of commercial scale gasifier

2013 26

Case 1 Case 2 Case 3O2/N2=25/75 O2/CO2=25/75 O2/CO2=35/65

Base data(Air blown)

Convert N2 to CO2

IncreaseO2

Decrease CO2

70TPH commercial gasifier









Impact of carbon deposition on sorbent

2013 28

Honeycomb desulfurization sorbent was cracked due to expansion of zinc ferrite particle through carbon deposition.

Honeycomb desulfurization sorbent

Countermeasure for carbon deposition

2013 29

① Boudouard reaction - CO → CO2 + C

② Water gas shift reaction - CO + H2O → CO2 + H2

③ Methanation - CO + 3H2 → CH4 + H2O

④ Reformation of methane - CH4 + H2O → CO + 3H2

←CO2 addition

←H2O addition （ CO2 increases)

Recirculated exhaust gas: Mixture of CO2 & H2O

Effect of each countermeasure (CRIEPI Report : M10012)

2013 30

Gas mixing ratio*2 (%)

*1: Weight of carbon deposition Weight of hole sample *2: Flow rate of additional gas Flow rate of syngas

Steam CO2 CO2+Steam (Exhaust gas)

Assumed exhaust gas composition

2013 31

Comparison of each countermeasure (CRIEPI Report : M10012 ,M12001)

Steam CO2 Recirculated exhasut gas

Effect to prevent Carbon deposition ◎ ▲ ○

Necessary gas volume ◎ ▲ ○

Necessary heat and in house power ▲ ○ ◎

Deterioration of desulfurization

catalyst ▲ ◎ ◎

Total evaluation ○ ▲ ◎

Detail of this penalty estimation will be explained in the 8th Conference on Sustainable Development of Energy, Water and Environmental Systems (27/9/2013)

Efficiency penalty of this countermeasure is less than 0.2 %.








4) Preparation toward next step 2013 32

High feasibility was confirmed

2013 33

<Examples of other reconsidered points> - Arrangement of heat exchangers of HRSG (To mitigate temperature deviation between heat exchangers)

- Temperature of HRSG exhaust gas (To keep higher exhaust gas temperature than acid dew-point)

Flue gas path was simplified ( It is difficult to control amount of gas flow)

50tpd coal gasification equipment

2013 34

The plan is under consideration for pilot scale development project. Necessary equipment was considered supposing existing 50tpd gasification equipment.

http://www.mhi.co.jp/discover/story/project02/story02.html

2013 35

Necessary equipment for pilot scale test

Tank trucks

Vaporizer Liquid CO2

Pump

Case2：Tank truck Method

Necessary Equipment

M P

M P

50tpd Gasifier

Case1：CE Method

CO2

M

M

Cold Evaporator

Vaporizer Compressor

Necessary Equipment

50tpd Gasifier

It was clarified that gasification tests are possible by installing minimum equipment to existing 50tpd gasifier.

Conclusion

2013 36

1 Experiments using 3t/D entrained flow gasifier and numerical simulation results clarified the concept of this system. 2 Countermeasure for carbon deposition was found out. 3 System arrangements by feasibility studies done by heavy industry manufacturer made this system feasible . 4 Toward next step, preparation for pilot scale experiments and additional considerations are under way.

2013 37

<Acknowledgement> Most part of this presentation has

been executed based on research funded by NEDO (New Energy and Industrial Technology Development Organization). Some works done by CRIEPI as in-house research.

Questions？

2013 38

Consideration on Cost of Electricity

2013 39

Energy and Environment Council of Japan was established on June 2011 to re-consider Japanese energy policy. One of a committees belonging to the council standardized method to evaluate Cost of Electricity of various power generation system.

Consideration on Cost of Electricity

2013 40

“Cost and performance baseline for fossil energy plants Vol1.rev2 Nov,2010”

Documents

Development of High-Efficiency Oxy-fuel IGCC System...Contents 1 Background & objective 2 Concept of High-Efficiency Oxy- fuel IGCC 3 Project status 1) Experimental study using 3TPD